Injection molding apparatus



NOV. 14, 1944. R P; PIPERQUX 2,362,583

INJECTION MOLDING APPARATUS Original Filed April 22, 1939 2 Sheets-Sheet l 8 wig/9 lNVENTOR Ren P piperoux Nov. 14, 1944. R. P. PIPE-:ROUX 2,362,583

INJECTION MOLDING APPARATUS Original Filed April 22. 1959 2 Sheets-Sheet 2 klez 57 ),/rT---LL i. i 2

INVENTOR v Rene P piPerQux Pnenied'uev. 14, '1944 UNITED srA'rEs" i PATENT zsezsss l r nene r. ripemnx, naam N. 1.,' mmm i CelaneseCoi-poration'el' America, acci-poration y of Delaware application april zz, issn, serial No.v

A further object of the invention is to provideI apparatus for the production of articles by in jection molding of thermoplastic materials which are uniform in appearance and that do not show discolored or oft-1uster seams, spots or weld lines due to the dow of molten material during the molding operation. i

A further object of the invention is to provide apparatus for centering and holding a metal in-` sert in the mold ina ilxedrm position during the molding operation. v

Other objects of the invention will appear from the following detailed description and drawings and will be pointed out in the claims.

While thepresent invention is particularly applicable to the production of a faucet handleas 'shown in the drawings, it is also applicable to the material thermoplastic material. Furthermore,v the ar- Original 203,476, Divided and this application -Decem ber 16, 1941. Serial No. 423,139 ,v

comme. (ci. n-izi The manufacture fof `articles `by injection molding of thermoplastic materials has been practiced for some time. piillculty, however, was experlenced in attempts to produce articles having a metal insert.' The 'articles yhad a wrinkled or warped appearance due to the shrinkage of the ticies unless made of absolute opaque thermoplastic material werenot of uniform color. -This was due tothe metalinsert allowing more light to pass through or be rei'lected from one part of the article than from another.- This was often the case when themetal insert tipped during the molding operation, which quite often happened even to theextent ofV allowing a part of the bare metal to showin the ilnished object. rlhe number 'ot rejects prevented commercial injecf' tion molding of thermoplastic materials into arproduction of other objects made with an insert i which requires exact placing in the mold to insure vinjection molding of plastic -materialfof even thickness and without forming objectionable-.weld

lines. These weld lines are very pronounced if a` pearl essence plastic material is employed.-

4In the drawings is shown the invention as applied to the manufacture of -a faucet handle. In

the respective views. the same reference numerals' refer to the same or similar elements:

f -ticles having a `metal insert. These objections I overcome by employing a metal insert of substantially thesame shape as the finished article such that the depth or thickness of the thermoplastic material is about the same over the article.

To lprevent the article from having unsightly weld marks I extrude the thermoplastic material in such a manner that the flow of the material is from the top center of the article. Thisplaces ,the weld, if` any, at the bottom or unseen part of the article. yA further advantage-gained by gating the. article at the top is that when em` 4playing pearl essence the luster or pearl effect is greatly enhanced. This is due to the longer flow ofthe thermoplastic material at the top surface of the articlevthus arranging the scales which produce' the pearl effect such that they are substantially parallel vto the surface of the article and notl standing on edge, i. e., normal to the surface Fig. 1 is a plan view, partly in section, of aw faucet handle constructed in accordance with .this

invention,

Fig. 2 is a sectional view `taken `on line 2-42'of Fi l,

gig. 3 is a sectional view taken on line of Fis. 2,

Fig-4 is a side view, partly in section, o! the handle shown in Fig. 1 and Fig. 5 is a cross-sectional view of a mold showing. the means for positioning and retaining a metal insert during the molding operation, and for releasing the molded article vupon opening the mold. y

of the article. The sprue being centered may be removed easily and the'spot from which it is cut may -be separated from theremaining surface by a groove vwhich breaks the continuity of the surface and makes any slight color difference im` noticeable. l A

Injection molding of articles containing metal or other inserts has in the past altered dimeumes in the positioning and retaining of thel insert in the mold. Due to thel viscosity of the-thermoplastic materials and the speed and pressure under which itis extruded into the mold, the retaining of `a metal insert in a ilxed position during the molding operation is very dimcult. I have overcome .this dimculty by a-m'old having a cam-operated positioning pin and also by a novel form of support for the metal insert. By these means the metal inserts are properly positioned in the mold and held there against displacement, l rotation. tipping and other movements during the injection of the thermoplastic material.

In accordance with myinvention, I provide ,apparatus for producing articles having a metal insert by injection molding a thermoplastic material, such as a derivative of cellulose,'into a mold containing the metal insert. This I accomplish by employing an insert of substantially the same contour as the finished article and position and retain this insert in an exact position during the molding operation by a support in the mold allowing only one position of the insert and providing a mold with a cam-operated pin for holding the insert on the support. The mold is gated so that the inJection of the material is at the top of the article instead of at the ends or sides, thereby eliminating objectionable weld lines at the points where the streams of molten -mavinyl compounds known in the trade as Alvar, Formvar, Butalvar, Vinal, etc.

Thethermoplastic materials may contain, be-

l sides the base such as the derivative of cellulose ,boiling or high boiling plasticizers, or mixtures of these, depending upon the type of article desired, as is well known in the art.

The present invention may be employed upon or in connection with any suitable extrusion or injection molding machiner especially of the cylinder and piston type, examples of which are the devices shown and described in U. S. Patent No.

-Any suitable temperature and pressure may be employed depending upon the plastic material beterial come together. The sprue is removed and at least a groove formed in the surface separating the spot from which the sprue is cut from the rest of the surface to break the continuity of the surface thus minimizing the visual effect of the two-tone color of the surface. If desired, a more intricate -embossed and/or enameledl design my be employed to completely eradicate the two-tone eect resulting from the removal of the sprue.

This invention may b`e employed in the production of faucet handles as shown in the drawings or it may be employedl in the production of other handles or articles having a metal or other preformed insert such as knobs for radios, light or ignition buttons for mounting on dash boards of automobiles, automobile gear shift handles, knobs and buttons for electrical control boards, typewriter keys, screw driver handles, furniture accessories, novelties, etc. The articles containing an insert may be made by injection molding of molding powder, grains, chips, flakes, cubes, etc., of thermoplastic material containing a derivative of cellulose such as an organic .derivative of cellulose. Organic derivatives of cellulose may be an organic acid ester of cellulose, a cellulose ether, a mixed ester of cellulose,'or a mixed esterether of cellulose. Examples oi' thel organic esters of cellulose are cellulose acetate, cellulose formate, cellulose propionate and cellulose butyrate. while examples of the cellulose ethers are ethyl celluolse, methyl cellulose and benzyl cellulose. Examples of mixed esters of cellulose are celluulose nitroacetate, cellulose aceto-butyrate and cellulose aceto-propionate, while examples of mixed ester-ethers oi' cellulose are benzyl cellulose acetate and methyl cellulose acetate. Mix` tures of any of the above derivatives of cellulose as well as nitrocellulose having a suitable degree of nltration may also be employed.

Any other suitable thermoplastic material mayl be employed such as those'containing artificial resins. Examples of such resins are the thermoplastic resins formed by the condensation or polymerization of formaldehyde and urea, phenol and formaldehyde, polyhydric alcohols and polybasic acids, toluene sulphonamide and aldehyde and the condensation or polymerization products of compounds containing the vinyl radical (CHztCH), for instance, acrylic and methacrylic acid esters, chlorinated derivatives of vinyl compounds and acid derivatives such as vinyl aceate, vinyl propionate, etc.. or mixtures of these,

ing extruded. In the extrusion of cellulose scetate and similar thermoplastic materials extremely high pressures may be employed. These may reach or exceed 15,000 pounds per square inch, but higher and lower pressures may be employed.'

The metal insert may be of any suitable metallic material. However, the insert may be i formed of a thermoplastic material having a l containing axially disposed teeth 1 adapted to higher melting point than that of the plastic material with which it is to be surrounded. For instance, the insert may be wood, Bakelite, pressed fiber, vulcanized iiber, etc. In either case the insert is preformed and is inserted, positioned and retained into the mold prior to the injection molding operation. Examples of suitable metals from whichv to form the metallic inserts are brass of various degrees of hardness, zinc alloy die casting metal, aluminum and its alloys. copper and iron or other alloys. l

The invention will now be explained by describing the production of a single article, reference being made to the drawings. The drawings show the invention employed in the production of faucet handles. The faucet handle comprises a metal insert 4 having a coating of thermoplastic material l surrounding at least a part of same and placed thereon by inlection "molding methods. In the case of a faucet handle the vmetal insert l is provided with a hub register with similar teeth on the male or stem pari; of a faucet. These teeth allow the positioning of the handle in any one of a number of positions depending upon the number of teeth. For the purpose of positioning the metal insert in the mold the metal insert is made with a flat surface l formed by omitting one tooth thereonor removing one tooth from the formed 'insert. 'I'his surface is preferably on the side of the hub opposite to a tapped hole 9 adapted to receive a set screw to retain the faucet handle on the male member of the faucet. The omission of one of the teeth 1 to form the flat surface 8 does not interfere with the positioning of the handle on the male member of the faucet yet this allows a means of positioning the metal insert in a mold and also acts as a steadying innuence during the molding operation due to the v extended ilat surface.

The article shown in Figs. 1 to 4 is formed in the mold shown in Fig. 5 which may be mountalso styrol and aldehyde reaction products of readily cut from particles aligning ascuas vided with a channel i3 acting as a gate through which the material is extruded into the cavity of the mold il from any suitable type of nozzle I5. As shown in the drawings. this produces an article having a sprue i6 centered in the front face of the article. This sprue may be l1 is cut into the article to separate the spot from `which the sprue was cut from theremaining surface of the article. As stated above, this breaks the continuity of the surface at'the placa where the color change practically unnoticeable. For most purposes this groove l1 maythen be filled in with a diilerent colored thermoplastic material or enamel and these colors may be used to distinguish, say, the hot and cold water faucets or light switch from ignition switch, etc. At the time the groove i1 is formed in the article thesurfaoe of the article within the groove may also be embossed with any suitable design, wording or connguration. The groove and any configuration within-its circumference may be cut into the thermoplastic material or it may be embossed therein using a heated stamping element. The employment of a heated element is preferred as the surface after which a groove color changes thus making said The injection molding machine is provided with a back mold face 2l in whichis rigidly mounted a male insert-retainingmember 22.

member 22 terminates at the interior o!` the mold in a support 23 'having teeth 24 correspond' ing to the grooves between the teeth 1 of the metal insert; nl ``member is aflat section corresponding to the -surface 8 of themetal in-` sert. `:By such a mounting the metal insert canl be placed. upon rthe male supporting member in only one position yet this does not interfere with` the placing of nished article on the male member ofthe faucet in any of thefpositions cor.r responding to Ythe number of 'teeth thereon. vIn

the vback face of the mold, at the side opposite to this flattened spaceion the supporting memi ber,.- is a channel 25 in which operates a pin 28 having a'-.taperedend 21. This tapered end of the pin is designed to direct the pin 26 into the ,hole l of the `metal insert thus bringing the metal insert to an exact 'position and retaining the same in that -position during the extrusion of Vthe material. 4The pin 26 is operated by vmeans of a cam 28 which is permanently attached by a new or the material, which when employing pearl essence in the lthermoplastic material, causes a flow of the material laying the-scales in a position more parallel to the surfacev of the article. The extrusion of the material, however,

being a considerable quantity in proportion to the size of the sprue and flowing as it does from the sprue out over the surface of the article.. tends tc lay the scales parallel with the surface of the article even at the spot from which the sprue is cut.

The above description of the now of material from the nozzle is process the cavity of the mold may be gated slightly different to produce different effects. Pearl essence effects are produced by small nakelike lustrous particles disseminated through a translucent carrying mass. If this mass is forced through an orifice `when in the plastic state. these lustrous particles will align themselves in the direction of the stream, the alignment beins more or less perfect dependent upon the velocity. If such a mass is forced or extruded through a sheet-like orifice, such as produced preferred but by a .modifiedi .back face of the mold.

means of-the pin 2l to -the-front face of the mold. The pin 28 is formed or` attached to a block 3i that acts as a cam follower and is adapted vto reciprocate in a channel 32 in the I'he block 2| is slotted as at 2l extends through the slot. Mounted in the block Il at the end opposite to the pin 28 is a spring-supporting pin 3| having mounted thereon a suitable spring 25 which abuts against the face 28-formed in the back face of the mold. The spring 28 tends to forcethe block towards the mold cavity thereby tending toforce the by the top of the insert and the mold cavity face positioned as shown in Fig. 5, the result will be a hat or entirely lustrous surface without marked configurations, or with practically an absence of configuration. This is caused by the face to the outside of the article. However, if the channel I8 is divided or quartered at or near the entrance to the mold cavity and especially if it branches out at a downward -angle the streams of plastic issuing therefrom are caused themselves with their fiat sur- 4 pin 28 into the insert I. Upon the separation of the mold faces for the purpose of removing the formed article and the insertion of a new insert, the back face of the mold moves along the cam 28 to the position shown in dotted lines in Fig. 5. As the back face of the mold travels rearwardly with respect ,to the cam 2B the cam face at I1 pulls the block Il in such a way that the pin 26 is pulled out of the insert and the formed article. The cam face 81 is so spaced and positioned that the pin 28 is removed from the metal insert just prior to that instant in which the knockout pin 28 operates to push the' formed article 'from the mold.

- It is to be understood that the foregoing detailed description is merely given. by way of illustration and that many variations may be made therein without departing `from the spirit of my invention.

Having described my invention, what I desire to secure by Letters Patent is:

`1. Apparatus for the production of injec- -*tion molded article containing a preformed insert adapted to enable the article to be secured to a stem or spindle by means of a set screw, comprising a mold having a front half and back .half movable with respect to each other, a support corresponding substantially to the stem or spindle to which the molded article is to be" secured and adapted to prevent rotation of the insert mounted thereon, a plunger movable transversely in the mold adapted to protrude through the mold space into engagementwith a set screw hole in an insert to hold the supported insert in a fixed position during molding and to provide for the molding of an aperture in alignment with the set screw hole in the insert, the support being so shaped as to position an insert,

33 and the camer and having a vplurality of axially disposed teeth and .a fiat surface produced bythe absence of one tooth so as 'to enter a correspondingly shaped recessin the insert.

I2. Apparatus for vthe production of an injection molded article containinga preformed insert adapted to enable the article to be secured to a vstem or spindle by means `ot ya. -set screw. comprising .a mold having a front half and back half movable with respect to each other. a support corresponding substantially-to vthestem or spindle to which the molded article is to be secured and adapted .to prevent rotation of the insert mounted ther-soma plunger movable transversely in the mold adapted .to lprotrude through with its set screw hole in register vwith theplungthe mold space into enzasement 'sith a set screw hole in an .insert to hold the supported insert `in fixed position during molding and to provide for the molding of'an aperture in alignment 'with the set screw hole in the insert, the support being so shaped as to position an insert with .its set screw hole in register with the plunger and having a plurality of axially disposed teeth and a nat surface produced by the absence of one tooth sofas to enter a correspondingly shaped recess in the insert, and a cam operating onthe plunger to ,move the same into and out of engagement with the insert as the mold halves move I towards and away from each other.

RENE P. PIPERoUx 

